Cold Spray

Coatings/Corrosion Prevention

Problem Statement: Cold Spray is a proven alternative to weld repair of US Navy ship and submarine metal components. Beginning in 2013, over 100 critical components were repaired using cold spray technology and returned to the Fleet; however, full potential of this technology was limited by available resources to develop procedures and execute repairs.

Innovation Solution: The NAVSEA enterprise expanded to 14 certified repair sites, developed a repository of reusable procedures, and executed Point of Need (PON) cold spray applications, including shipboard repairs. These accomplishments demonstrate the value of cold spray while identifying technical, workforce, equipment, and process requirements needed for broader use across the DoN maintenance enterprise. Building on this, NAVSEA established a Cold Spray Roadmap addressing the ten identified problem areas to expand capacity, institutionalize processes, and increase Fleet readiness and material condition.

Benefits to the DoW: Expanding this repair option to other components and continued refinement have significant potential to expedite DoW maintenance and repairs, saving time and money and enabling the warfighter to remain in the fight and succeed.

Cross-Service Applicability: Cold spray technology is service agnostic, and cross-service use is increasing. Technical exchange events have promoted cold spray use across the DoW. The technology has expanded beyond current Navy use cases to repair high-value components wherever needed.

Innovation Challenges: Agility and responsiveness are impacted by equipment size and interchangeability, limits in skilled workforce and industrial capacity, qualification timelines, and material lead times. Adherence to the Cold Spray Roadmap and completion of initiatives such as “Just Spray It” guidance will better position the DoW to respond to routine repairs and urgent needs of warfighters in remote or austere locations.

Technical Maturity / Demonstration Results: NAVSEA established technical requirements to control quality and drive efficiency, including compatible metal powder selection and Qualified Spray Procedures (QSPs) that define critical parameters and testing needed for acceptable adhesion and mechanical performance.

In 2025, shipboard repair of a SUBSAFE component on USS Virginia (SSN-774) prevented a 45-day unplanned docking. Completion and certification marked the first time a component was worked under SUBSAFE Re-entry controls with Cold Spray.

In 2026, USS Anchorage experienced a pump shaft problem while preparing to get underway. The shaft was repaired and returned the next day, proving confidence in this technology. Similarly, repair of a lube oil pump shaft for USS Carter Hall was completed in under a week. These successes exemplify cold spray capabilities, demonstrating speed, responsiveness, and tangible Fleet readiness impact.